Turbocharger With Twin Parallel Compressor Impellers And Having Center Housing Features For Conditioning Flow In The Rear Impeller

ABSTRACT

A turbocharger having twin radial compressor impellers arranged back-to-back has a center housing that conditions flow going into the second (rear) impeller via either a ported shroud for the second impeller or inlet guide vanes for the second impeller. The ported shroud is defined at least in part by the center housing. In the inlet guide vane embodiment, the inlet guide vanes are defined by the center housing.

BACKGROUND OF THE INVENTION

The present invention relates to compressors for turbochargers, and more particularly to twin-impeller centrifugal (or radial) compressors and to turbochargers that include such compressors.

Radial compressors are used in various types of turbomachinery, including turbochargers for internal combustion engine systems. A radial compressor generally includes at least one compressor stage formed by a rotating impeller mounted on a shaft within a compressor housing. The housing defines an inlet flow path that typically leads into the impeller in a generally axial direction. The impeller includes a hub and a plurality of blades spaced about its circumference and extending out from the hub. The impeller is configured to receive fluid in the axial direction and to compress the fluid and discharge the fluid in a generally radially outward direction into a volute defined by the compressor housing. The housing includes a wall or shroud that extends proximate the tips of the impeller blades and, together with the hub of the impeller, defines the main flow path through the impeller.

Some compressor wheels have two impellers arranged back-to-back such that fluid enters one impeller in one axial direction and enters the other impeller in an opposite axial direction. It is a simple matter to supply air to the impeller on the outer end of the device (referred to herein as the “first” or “front” impeller), as the air comes in axially from outside the turbomachinery device (e.g., a turbocharger), via a suitable inlet conduit. The other impeller (referred to herein as the “second” or “rear” impeller), however, is typically up against other structure. For example, in a turbocharger, the rear impeller would typically be up against a bearing housing or center housing. Accordingly, air generally must be routed initially in a radially inward direction and then must be turned roughly 90 degrees to enter the rear impeller axially. Providing a reasonably uniform flow field into the rear impeller becomes a challenge. A uniform flow field is important to performance, particularly as regard the stall margin of the compressor.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure deals generally with flow-conditioning into the rear impeller of a parallel twin-impeller compressor for a turbocharger, such as for improving stall margin of the compressor. More particularly, the present disclosure describes such flow-conditioning accomplished by structures that are defined at least in part, and in some cases wholly, by the center housing of the turbocharger.

In one embodiment described herein, a turbocharger comprises a turbine mounted on a rotatable shaft for rotation about an axis of the shaft, and a radial compressor comprising a compressor wheel mounted on the shaft and disposed within a compressor housing. The compressor wheel comprises a first impeller and a second impeller each having a hub and a plurality of compressor blades extending from the hub, a back side of the first impeller being adjacent a back side of the second impeller such that the impellers are in a back-to-back arrangement and air enters the impellers in oppositely directed axial directions. The compressor housing defines an inlet to the first impeller and defines a common volute that receives pressurized fluid from the first and second impellers via a common diffuser leading from the impellers into the volute. The compressor housing also defines a first shroud that is adjacent the tips of the blades of the first impeller.

The turbocharger includes a center housing mounted between the compressor housing and the turbine housing and containing bearings for the shaft. The center housing defines an inlet flow path for the second impeller. There is a second shroud that is adjacent the tips of the blades of the second impeller.

The turbocharger further includes a shroud ring mounted between the center housing and the compressor housing. The shroud ring defines at least part of the second shroud. The shroud ring further defines one wall of the common diffuser.

The second shroud defines at least one bleed port therethrough and the center housing at least partially defines a bleed flow passage leading from the at least one bleed port into the inlet flow path for the second impeller at a position upstream of the at least one bleed port. Thus, fluid can pass in either direction between the inlet flow path and the second impeller via the at least one bleed port and the bleed flow passage. This “ported shroud” arrangement can be beneficial to stall margin.

In one embodiment, the at least one bleed port is formed by a generally annular space defined between the shroud ring and the center housing. The generally annular space also partially defines the bleed flow passage.

In one embodiment, the center housing defines a part of the bleed flow passage that leads from the generally annular space into the inlet flow path for the second impeller. In a particular embodiment this part of the bleed flow passage comprises an opening. For example, the opening can be an elongate circumferentially extending opening.

In another embodiment described herein, a turbocharger comprises a turbine mounted on a rotatable shaft for rotation about an axis of the shaft, and a radial compressor comprising a compressor wheel mounted on the shaft and disposed within a compressor housing, the compressor wheel comprising a first impeller and a second impeller each having a hub and a plurality of compressor blades extending from the hub, a back side of the first impeller being adjacent a back side of the second impeller such that the impellers are in a back-to-back arrangement and air enters the impellers in oppositely directed axial directions. The compressor housing defines an inlet to the first impeller and defines a common volute that receives pressurized fluid from the first and second impellers via a common diffuser leading from the impellers into the volute. The compressor housing defines a first shroud that is adjacent the tips of the blades of the first impeller, and there is a second shroud adjacent the tips of the blades of the second impeller.

The turbocharger includes a center housing mounted between the compressor housing and the turbine housing and containing bearings for the shaft, the center housing defining an inlet flow path for the second impeller.

The center housing defines inlet guide vanes disposed within the inlet flow path for the second impeller for conditioning flow into the second impeller.

In one embodiment, the inlet flow path for the second impeller extends substantially 360 degrees about the axis, and the compressor housing defines an entrance passage into the inlet flow path for the second impeller, the entrance passage extending along a generally radial direction into the inlet flow path for the second impeller.

In a particular embodiment, some of the inlet guide vanes have configuration differences relative to others of the inlet guide vanes. The configuration differences can include setting angle differences and/or differences in vane length along a direction of flow in the inlet flow path to the second impeller and/or differences in camber of the vanes.

In the embodiments described herein, the “center housing,” which houses the bearings and also defines the bleed flow passage and/or the inlet guide vanes, is a one-piece integrally formed structure (as opposed to an assembly of separately formed parts one of which houses the bearings and another of which defines the bleed flow passage and/or the inlet guide vanes).

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a cross-sectional view of a turbocharger in accordance with one embodiment of the present invention;

FIG. 2 is a cross-sectional view of a portion of the turbocharger of FIG. 1;

FIG. 3 is a cross-sectional view of the portion shown in FIG. 2, but on a different plane from FIG. 2;

FIG. 4 is an exploded perspective view of an assembly including a center housing and a shroud ring as used in the turbocharger of FIG. 1;

FIG. 5 is an axially sectioned perspective view of the turbocharger of FIG. 1;

FIG. 6 is a perspective view, partly sectioned, of a turbocharger in accordance with another embodiment of the invention;

FIG. 7 is an axial cross-sectional view of the turbocharger of FIG. 6;

FIG. 8 is a perspective view of a center housing, partly sectioned, used in the turbocharger of FIG. 6;

FIG. 9 is a perspective view of the center housing of FIG. 8, sectioned to show details of the inlet guide vanes;

FIG. 10 is an end view of the sectioned center housing of FIG. 9; and

FIG. 11 is a perspective view of the center housing of FIG. 8.

DETAILED DESCRIPTION OF THE DRAWINGS

The present inventions now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

FIG. 1 shows a turbocharger 100 having a twin-impeller compressor, in accordance with one embodiment of the invention. The turbocharger 100 includes a rotary shaft 102 on one end of which a turbine wheel 103 is mounted. The turbine section of the turbocharger 100 includes a turbine housing (not shown) that defines a turbine volute arranged to direct fluid to the turbine wheel 103. Exhaust gases from an engine (not shown) are fed into the turbine volute and the gases then pass through the turbine wheel 103 and are expanded so that the turbine wheel 103 is rotatably driven, thus rotatably driving the shaft 102. The expanded gases are discharged from the turbine housing. The turbine can be a radial turbine in which the flow enters the turbine in a generally radially inward direction; however, the invention is not limited to any particular turbine arrangement. Furthermore, the turbocharger could include means other than a turbine for driving the shaft 102, such as an electric motor.

The shaft 102 passes through a center housing 110 of the turbocharger. The center housing connects the turbine housing with a compressor housing 130 of the turbocharger as further described below. The center housing contains bearings 108 for the shaft 102. The compressor housing 130 is affixed to the center housing 110 in suitable fashion, such as with threaded fasteners (not shown) or the like. Preferably the center housing is a one-piece integrally formed structure.

Mounted on an opposite end of the shaft 102 from the turbine wheel 103 is a compressor wheel 140 comprising a first impeller 142 and a second impeller 144. Surrounding the compressor wheel is the compressor housing 130. A forward portion of the compressor housing defines a compressor inlet 132 leading into the first impeller 142.

The first impeller 142 and second impeller 144 are mounted back-to-back; that is, the downstream side of the first impeller 142 is nearer the turbine than is the upstream side of the impeller, while the downstream side of the second impeller 144 is farther from the turbine than is the upstream side of the impeller. Air enters the inlet 132 axially and goes straight into the first impeller 142. With respect to the second impeller 144, however, air must enter it in an opposite axial direction because of the back-to-back arrangement of the two impellers. Accordingly, as further described below, the air must be routed from outside the turbocharger in a generally radially inward direction toward the axis of the turbocharger, and then must be turned approximately 90 degrees to flow axially into the second impeller 144. The arrangement for accomplishing this in an advantageous fashion is one of the key features of the present disclosure.

Before describing the second impeller in detail, however, the compressor housing 130 is described. A common scroll or volute 134 is defined by the compressor housing. Air pressurized by the two impellers 142, 144 is discharged from the impellers in a generally radially outward direction (although of course the flow has a significant circumferential or swirl component of velocity imparted by the compressor wheel) into a common diffuser 135, and the air flows outward through the diffuser and is diffused (i.e., its velocity drops and its static pressure rises) and is discharged into the common volute 134. The compressor housing defines a discharge conduit (not visible in FIG. 1) for discharging pressurized air from the volute 134 for supply to the intake of the internal combustion engine.

The compressor housing includes a first shroud 136 that extends circumferentially about the first impeller 142 closely adjacent to the tips of the blades of the impeller; the main flow path through the first impeller is defined between the first shroud and the hub of the impeller. The first shroud optionally can include flow recirculation features such as a bleed port 137 located adjacent the first impeller 142, a recirculation flow passage 138, and a bleed flow injection port 139 spaced upstream of the first impeller for allowing recirculation of flow for aiding stall margin of the compressor. In the illustrated embodiment, the inlet 132 to the first impeller is defined by a generally ring-shaped part that is separate from the rest of the compressor housing 130, and the injection port 139 is defined between this ring-shaped part and the first shroud 136 defined by the compressor housing. Alternatively, however, the inlet 132 could be integral with the rest of the compressor housing.

Turning now to the second impeller 144 and associate features, with primary reference to FIGS. 2 and 3, a second shroud 146 for the second impeller is defined at least in part by a shroud ring 148 that is separate from the compressor housing 130 and the center housing 110. The shroud ring 148 is mounted between the center housing 110 and the compressor housing 130, and is fastened to the center housing by fasteners 149 (FIGS. 1 and 4). In the illustrated embodiment, the shroud ring defines part of the second shroud 146 and the center housing 110 defines the remainder of the second shroud. The common diffuser 135 is formed between a wall of the compressor housing 130 and a wall of the shroud ring 148. It will also be noted from FIG. 1 that the compressor housing 130 defines a space or receptacle into which a partial assembly (comprising the shaft 102 and compressor wheel 140, the shroud ring 148, and the center housing 110) is received, in a right-to-left direction in FIG. 1, until an outer flange portion 112 of the center housing abuts an annular surface defined by the compressor housing. The abutment of the flange portion 112 with the annular surface on the compressor housing ensures that the shroud ring 148 is properly located in an axial sense with respect to the compressor housing (so that, for example, the compressor wheel 140 has the correct axial position with respect to the first shroud 136 and so that the diffuser 135 has the intended axial width dimension). Additionally, the annular surface abutted by the center housing flange portion 112 is surrounded by a step that locates the flange portion 112 properly in a radial sense (so that, for example, the compressor wheel 140 has the correct radial position with respect to the first shroud 136).

In accordance with this embodiment of the invention, the second shroud 146 defines at least one bleed port 150 therethrough and the center housing 110 at least partially defines a bleed flow passage 152 leading from the at least one bleed port into the inlet flow path for the second impeller 144 at a position upstream of the at least one bleed port 150 such that fluid can pass in either direction between the inlet flow path and the second impeller via the at least one bleed port 150 and the bleed flow passage 152.

In the illustrated embodiment, the at least one bleed port 150 is formed by a generally annular space defined between the shroud ring 148 and the center housing 110. This generally annular space partially defines the bleed flow passage 152. Additionally, the center housing defines a part of the bleed flow passage 152 that leads from the generally annular space into the inlet flow path for the second impeller. More particularly, this part of the bleed flow passage comprises an opening 154 defined in the center housing 110. The opening 154 in the illustrated embodiment is an elongate circumferentially extending opening, as best seen in FIG. 4.

The upstream portion of an impeller that the fluid first encounters is often referred to as the inducer of the impeller. When the flow rate through the compressor is reduced while maintaining pressure ratio at a relatively high level, at some point the surge line of the compressor map is encountered. Surging at relatively high pressure ratios typically occurs because of stalling of the inducer of one or both impellers, wherein the flow at the blade tips of the inducer begins locally to recirculate, thereby reducing the effective flow area of the inducer. In contrast, below a certain pressure ratio, surging typically is the result of stalling of the diffuser. The surge line of many compressors has a kink or “knee” above which surging is caused by inducer stall, and below which surging is caused by diffuser stall.

The current embodiment of the present invention particularly addresses surging above the knee caused by inducer stall. In accordance with the invention, the ported second shroud 146 is employed in order to delay the onset of inducer stall of the second impeller 144 to higher pressure ratios at flow (or, stated differently, to lower flows at pressure ratio). Thus, fluid entering the inducer of the second impeller 144 near the blade tips potentially can enter the bleed port 150 and flow generally radially outwardly through the bleed flow passage 152 and exit through the opening 154 into the inlet flow path for the second impeller. Fluid can also pass in the reverse direction from the inlet flow path through the opening 154 into the bleed flow passage 152 and through the port 150 into the inducer of the second impeller. The direction of flow depends on the sense of the pressure gradient between the inducer location and the upstream inlet flow path location.

At higher pressure ratios, where inducer stall of the second impeller 144 would ordinarily begin to occur, the ported second shroud (in comparison with an otherwise identical non-ported shroud) can delay the onset of surge. It is believed that at near-surge conditions the ported shroud allows fluid to pass into the bleed flow passage 152 and through the opening 154 back into the inlet flow path, and thereby prevents or reduces the local flow recirculation in the inducer tip region that normally attends inducer stall and surge.

As previously described in connection with FIG. 1, the compressor in accordance with the current embodiment of the invention can also include a ported first shroud 136. Alternatively, the compressor can have a non-ported first shroud.

Referring to FIG. 1, one of the fasteners 149 for the shroud ring 148 has a through bore that communicates with the hole 114 in the shroud ring into which the fastener is received. The center housing 110 additionally defines a passage 115 that communicates with the hole 114, and a passage 116 that communicates with the passage 115 and extends into the bore of the center housing in which a seal 109 for the rotor shaft 102 is located. In this manner, pressurized air from the diffuser 135 is communicated via the hole 114 and the passages 115, 116 to the seal 109 for pressurizing the seal.

A second embodiment of the invention is illustrated in FIGS. 6 through 11. The turbocharger 200 depicted in FIGS. 6 and 7 is similar in many respects to the turbocharger 100 described above, differing primarily in terms of the structure and arrangement of the center housing 210 and compressor housing 230. The turbocharger 200 includes a turbine wheel 203 mounted on one end of a shaft 202, and a compressor wheel 240 mounted on the other end of the shaft 202. The shaft is supported in bearings 208 mounted within the center housing 210. The turbine wheel 203 is contained within a turbine housing 220, which is affixed to the center housing 210 such as by the illustrated V-band shown in FIG. 7. The compressor wheel 240 is contained with the compressor housing 230. The compressor wheel is a twin-impeller wheel having a first impeller 242 and a second impeller 244 mounted back-to-back. Flow enters the first impeller 242 via a first inlet conduit 232, which leads the flow axially into the first impeller. Flow enters the second impeller 244 via a second inlet conduit 233, which leads the flow radially inwardly into an annular space 228 that surrounds a portion of the center housing 110. This portion of the center housing defines the inlet flow path for the second impeller 244. The fluid is distributed around the annular space 228 and flows generally radially inwardly through the inlet flow path and is then turned approximately 90 degrees to enter the second impeller 244 in a generally axial direction.

In accordance with the second embodiment of the invention, and with primary reference to FIGS. 8-11, the center housing 210 is an integral one-piece structure that includes a portion defining a second shroud 246 for the second impeller 244 and also defining one wall of a common diffuser 235 (FIG. 7) for the compressor wheel. The center housing 210 also defines inlet guide vanes 250 in the inlet flow path for the second impeller 244. Flow entering through the inlet conduit 233 (FIG. 7) first encounters a wedge-shaped member 252, which splits the flow into two portions, one of which proceeds generally clockwise through the annular space 228 and the other of which proceeds generally counterclockwise through the annular space 228, whereupon these two flows encounter the inlet guide vanes 250. Referring particularly to FIG. 8, the clockwise flow encounters inlet guide vanes 250 a, 250 b, and 250 c. In the illustrated embodiment, these inlet guide vanes are not identical in configuration. Specifically, the inlet guide vanes 250 a-250 c differ in setting angle with respect to the radial direction and also differ in length in the flow direction as well as the amount of camber of the vanes.

The inlet guide vanes 250 d-250 f for the counterclockwise flow portion are arranged in mirror image to the inlet guide vanes 250 a-250 c. Diametrically opposite from the wedge-shaped member 252 is a bird wing-shaped member 254 that also serves to help guide the flow into the second impeller. Detailed flow studies, such as CFD (computational fluid dynamics), can be used for tailoring the configurations of the inlet guide vanes 250 and the members 252 and 254.

It will be noted from FIG. 7 that the compressor housing 230 defines a space or receptacle into which a partial assembly (comprising the shaft 202 and compressor wheel 240, and the center housing 210) is received, in a right-to-left direction in FIG. 7, until an outer flange portion 212 of the center housing abuts an annular surface defined by the compressor housing. The abutment of the flange portion 212 with the annular surface on the compressor housing ensures that the portion of the center housing defining the second shroud 246 is properly located in an axial sense with respect to the compressor housing (and so that, for example, the compressor wheel 240 has the correct axial position with respect to the first shroud 236 and so that the diffuser 235 has the intended axial width dimension). Additionally, the annular surface abutted by the center housing flange portion 212 is surrounded by a step that locates the flange portion 212 properly in a radial sense (so that, for example, the compressor wheel 240 has the correct radial position with respect to the first shroud 236).

The inlet guide vanes 250 of the second embodiment are configured to condition the flow that enters the second impeller 244. In particular, the inlet guide vanes are configured to alter or regulate the direction of the flow in order to improve the uniformity of the flow around the circumference. More-uniform flow generally leads to greater stability of the compressor and improved surge margin.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

That which is claimed:
 1. A turbocharger, comprising: a turbine mounted on a rotatable shaft for rotation about an axis of the shaft; a radial compressor comprising a compressor wheel mounted on the shaft and disposed within a compressor housing, the compressor wheel comprising a first impeller and a second impeller each having a hub and a plurality of compressor blades extending from the hub, a back side of the first impeller being adjacent a back side of the second impeller such that the impellers are in a back-to-back arrangement and air enters the impellers in oppositely directed axial directions, the compressor housing defining an inlet to the first impeller and defining a common volute that receives pressurized fluid from the first and second impellers via a common diffuser leading from the respective impellers into the volute, the compressor housing defining a first shroud that is adjacent tips of the blades of the first impeller, and wherein a second shroud is adjacent tips of the blades of the second impeller; a center housing mounted between the compressor housing and the turbine housing and containing bearings for the shaft, the center housing defining an inlet flow path for the second impeller; a shroud ring mounted between the center housing and the compressor housing, wherein the shroud ring defines part of the second shroud and the center housing defines the remainder of the second shroud, the shroud ring further defining one wall of the common diffuser; wherein the second shroud defines at least one bleed port therethrough and the center housing at least partially defines a bleed flow passage leading from said at least one bleed port into the inlet flow path for the second impeller at a position upstream of said at least one bleed port such that fluid can pass in either direction between the inlet flow path and the second impeller via said at least one bleed port and said bleed flow passage.
 2. The turbocharger of claim 1, wherein said at least one bleed port is formed by a generally annular space defined between the shroud ring and the center housing.
 3. The turbocharger of claim 2, wherein said generally annular space partially defines said bleed flow passage.
 4. The turbocharger of claim 3, wherein the center housing defines a part of said bleed flow passage that leads from said generally annular space into the inlet flow path for the second impeller.
 5. The turbocharger of claim 4, wherein said part of said bleed flow passage comprises an opening.
 6. The turbocharger of claim 5, wherein said opening is an elongate circumferentially extending opening.
 7. The turbocharger of claim 1, wherein the center housing is a one-piece integrally formed structure.
 8. A turbocharger, comprising: a turbine mounted on a rotatable shaft for rotation about an axis of the shaft; a radial compressor comprising a compressor wheel mounted on the shaft and disposed within a compressor housing, the compressor wheel comprising a first impeller and a second impeller each having a hub and a plurality of compressor blades extending from the hub, a back side of the first impeller being adjacent a back side of the second impeller such that the impellers are in a back-to-back arrangement and air enters the impellers in oppositely directed axial directions, the compressor housing defining an inlet to the first impeller and defining a common volute that receives pressurized fluid from the first and second impellers via a common diffuser leading from the impellers into the volute, the compressor housing defining a first shroud that is adjacent tips of the blades of the first impeller, and wherein a second shroud is adjacent tips of the blades of the second impeller; and a center housing mounted between the compressor housing and the turbine housing and containing bearings for the shaft, the center housing defining an inlet flow path for the second impeller; wherein the center housing defines inlet guide vanes disposed within the inlet flow path for the second impeller for conditioning flow into the second impeller.
 9. The turbocharger of claim 8, wherein the inlet flow path for the second impeller extends substantially 360 degrees about the axis, and the compressor housing defines an entrance passage into the inlet flow path for the second impeller, the entrance passage extending along a generally radial direction into the inlet flow path for the second impeller.
 10. The turbocharger of claim 9, wherein some of the inlet guide vanes have configuration differences relative to others of the inlet guide vanes.
 11. The turbocharger of claim 10, wherein the configuration differences include setting angle differences.
 12. The turbocharger of claim 10, wherein the configuration differences include differences in length along a direction of flow in the inlet flow path to the second impeller. 